Straight face vinyl siding

ABSTRACT

The present invention is a vinyl siding panel and a method of making the vinyl siding panel. The vinyl siding panel comprises a planar portion extending the longitudinal length of the vinyl siding panel. The planar portion comprises a first edge and a second edge. The width from the first edge to the second edge is at least about 4.0 inches. The planar portion has a surface variance of less than about 0.05 inches relative to an imaginary straight line connecting the first edge and the second edge, and the radius curvature between the first edge and the second edge is at least about 85 inches.

This application is a continuation of U.S. Design application Ser. No.29/133,077, entitled STRAIGHT FACE, FOAM-BACKED, VINYL SIDING PANEL,filed Nov. 20, 2000.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to vinyl siding and, moreparticularly, to vinyl siding having at least one relatively straight,planar portion.

Vinyl siding may be produced by extruding at least one vinylcomposition. For example, vinyl siding can be made by co-extruding avinyl substrate and a vinyl capstock. The extruded vinyl is passedthrough a calibrator, e.g., a die, to obtain a final net shape. However,as the vinyl cools after passing through the calibrator, it has aninherent tendency to oil can. As is well known in the art, oil canningrefers to the inherent tendency of a sheet of vinyl to curve in either aconcave or convex direction as it cools.

As a result of the oil canning effect, it has been believed by thoseskilled in the art that it is not possible to produce vinyl sidinghaving at least one relatively straight, planar portion. Thus, thedesigns of vinyl siding have been limited. Vinyl siding commonly has atleast one horizontal row. Each row of the siding is subject to the oilcanning effect. Consequently, in order to limit the oil canning effect,it has been tried to limit the width of each row and the height of eachseam connecting adjacent rows. Moreover, it is common to produce thevinyl siding such that each row already has a significant amount ofcurvature as it exits the calibrator so as to of each seam connectingadjacent rows. Moreover, it is common to produce the vinyl siding suchthat each row already has a significant amount of curvature as it exitsthe calibrator so as to minimize the oil canning effect. These designconsiderations have limited and/or diminished the appearance of thevinyl siding. Therefore, a need exists for a vinyl siding panel that hasat least one relatively straight, planar portion despite the inherenttendency of vinyl siding to oil can.

One embodiment of the present invention is a vinyl siding panelcomprising a planar portion extending the longitudinal length of thevinyl siding panel. The planar portion comprises a first edge and asecond edge. The width from the first edge to the second edge is atleast about 4.0 inches. In addition, the planar portion has a surfacevariance of less than about 0.05 inches relative to an imaginarystraight line connecting the first edge and the second edge.

A second embodiment of the present invention is a vinyl siding panelcomprising a planar portion extending the longitudinal length of thevinyl siding panel. The planar portion comprises a first edge and asecond edge, wherein the width from the first edge to the second edge isat least about 4.0 inches. In addition, the radius curvature between thefirst edge and the second edge is at least about 85 inches.

A third embodiment of the present invention is a method of producing avinyl siding panel having a substantially straight, planar portion. Themethod comprises extruding at least one vinyl composition and passingthe vinyl composition(s) through a calibrator defining a passagewaycorresponding to the substantially straight, planar portion. Thepassageway has a first edge and a second edge. The width from the firstedge to the second edge is at least about 4.0 inches, and the surfacevariance is less than about 0.05 inches relative to an imaginarystraight line connecting the first edge and the second edge.

A fourth embodiment of the present invention is also a method ofproducing a vinyl siding panel having a substantially straight, planarportion. In this embodiment, the method comprises extruding at least onevinyl composition. The vinyl is then passed through a calibratordefining a passageway corresponding to the substantially straight,planar portion. The passageway has a first edge and a second edge. Thewidth is at least about 4.0 inches from the first edge to the secondedge, and the radius curvature between the first edge and the secondedge is at least about 85 inches.

In addition to the novel features and advantages mentioned above, otherobjects and advantages of the present invention will be readily apparentfrom the following descriptions of the drawings and exemplaryembodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a vinyl siding panel havingsignificantly curved rows.

FIG. 2 is a side elevation view of one embodiment of a vinyl sidingpanel of the present invention.

FIG. 3 is a side elevation view of one embodiment of a calibrator of thepresent invention.

FIG. 4 is a side elevation view of one embodiment of a vinyl sidingpanel of the present invention that includes a reinforcement panel.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

The present invention is directed to vinyl siding having at least onerelatively straight, planar portion. In addition, the present inventionincludes a method of making vinyl siding having at least one relativelystraight, planar portion.

FIG. 1 shows an example of a vinyl siding panel 10 having a plurality ofcurved rows 12. Each of the rows 12 has an edge 14 and an edge 16. Thedegree of curvature between edge 14 and edge 16 can be measured in atleast a couple different ways. In the first method, an imaginarystraight line a is made between edge 14 and edge 16. The surfacevariance is then measured between the outer surface of the vinyl sidingpanel 10 and the line a as indicated by arrow b and arrow c.Alternatively, the radius curvature can be measured between edge 14 andedge 16.

FIG. 2 illustrates one example of a vinyl siding panel 20 of the presentinvention. In this example, the vinyl siding panel 20 is comprised of arow 22, a row 24, and a row 26. In addition, the vinyl siding panel 20may include a nailing strip 28, a tongue 30, and a groove 32. Nails orany other suitable mechanical fastening means may be extended throughapertures in the nailing strip 28 in order to secure the vinyl sidingpanel 20 to a building structure. The tongue 30 is adapted to fit in thegroove of another siding panel when installed on a building structure.Likewise, the groove 32 is adapted to receive the tongue of anothersiding panel when installed on a building structure.

Each of the rows 22, 24, 26 is a planar portion. Row 22 has an edge 34and edge 36. Row 24 has an edge 38 and an edge 40, and row 26 has anedge 42 and an edge 44. The nailing strip 28 and the tongue 30 areconnected to the edge 34 of row 22. Edge 36 of row 22 is connected toedge 38 of row 24 by seam 46. Similarly, edge 40 of row 24 is connectedto edge 42 of row 26 by seam 48. As a result, this example of the vinylsiding panel 20 has a stepped contour.

As in this example, it is preferred that each of the rows 22, 24, 26 aresubstantially similar. However, it should be recognized that a vinylsiding panel of the present invention may have only one relativelystraight, planar portion. It should also be recognized that a vinylsiding panel of the present invention may have any plural number ofrelatively straight, planar portions.

For ease of description, the dimensions of a planar portion of thepresent invention will be described with regard to row 24 of vinylsiding panel 20. The width of row 24 from edge 38 to edge 40 is at leastabout 4.0 inches, more preferably at least about 5.0 inches, and stillmore preferably at least about 6.0 inches. The surface variance, asdefined with regard to FIG. 1, from edge 38 to edge 40 is less thanabout 0.05 inches, more preferably less than about 0.04 inches, andstill more preferably less than about 0.03125 inches. In addition, theradius curvature from edge 38 to edge 40 is at least about 85 inches,more preferably at least about 117 inches, and even more preferably atleast about 148 inches.

The row 24 may have any desired thickness from its outer surface to itsinner surface. However, it is preferred that the row 24 has an averagethickness in the range from about 0.040 inches to about 0.050 inches.More preferably, the average thickness of the row 24 is in the rangefrom about 0.041 inches and 0.046 inches.

The inventors have discovered that the height of the seams 46, 48 may begreater than in conventional vinyl siding. In fact, it is believed thatthe increased height of the seams 46, 48 may facilitate the productionof the vinyl siding of the present invention. In particular, the heightof each of the seams 38, 40 may be at least about 0.5 inches. Morepreferably, the height of each of the seams 38, 40 may be at least about0.6 inches.

If desired, a reinforcement panel may be secured to, or positionedbehind, the inner surface of the vinyl siding panel 20. For example, afoam reinforcement panel may be secured to the inner surface of thevinyl siding panel 20 by an adhesive. The reinforcement panel may tendto further straighten out rows 22, 24, 26 of the vinyl siding panel 20.Nevertheless, it should be recognized that the dimensions of the planarportion(s) discussed above are taken prior to the application of areinforcement panel or any other straightening means. FIG. 4 shows anexemplary embodiment in which a reinforcement panel 90 is secured to thevinyl siding.

It is preferred that the vinyl siding meets or exceeds the ASTM D3679standard. The vinyl siding of the present invention may be made from anyknown, suitable, or conventional vinyl composition(s). For example, thevinyl siding may be comprised of a vinyl substrate layer and an optionalvinyl capstock layer. The vinyl composition(s) may include one or moreadditives. For instance, the vinyl composition(s) may include one ormore additives to improve processing, durability, weatherability,resistance to ultraviolet (UV) degradation, impact resistance, and otherqualities of vinyl siding. An example of a weathering agent is titaniumdioxide, and examples of a vinyl substrate composition and a vinylcapstock composition are polyvinyl chloride (PVC) compositions. Forinstance, these compositions may include the following ingredients inabout the following amounts:

VINYL SUBSTRATE COMPOSITION PVC resin 100 Tin Stabilizer(s) 0.5–2.0Processing Aid(s)   0–2.0 Lubricant(s) 1.5–3.5 Impact Modifier(s)2.0–6.0 Mineral Filler(s)  0–12 Weathering Agent(s) 0.5–12  Colorant(s)As Desired

VINYL CAPSTOCK COMPOSITION PVC resin 100 Tin Stabilizer(s) 0.5–2.0Processing Aid(s)   0–2.0 Lubricant(s) 1.5–3.5 Impact Modifier(s)2.0–6.0 Weathering Agent(s)  9–11 Colorant(s) As Desired

Although the present invention has been described primarily with regardto vinyl siding, alternative embodiments of the present inventioninclude panels made from other extrudable, plastic materials. Forexample, panels of the present invention may also be made frompolystyrene, acrylonitrile-butadiene-styrene (ABS), nylon,ethylene-vinyl acetate (EVA), polycarbonate, polyethylene (PE),polypropylene (PP), polyethylene terephthalate (PET), thermoplasticolefins, acrylonitrile-styrene-acrylic (ASA), other similar orconventional plastics, and alloys, blends, and coextrusions of theseresins.

The vinyl siding of the present invention may be manufactured byextruding at least one vinyl composition. The vinyl is then passedthrough a calibrator. FIG. 3 shows an example of a calibrator 50.Optionally, a preforming guide, another calibrator, and/or any otherdesired manufacturing components may be interposed between the extruderand the calibrator 50. The preforming guide and the other calibrator maybe used to form the vinyl into the general shape of the vinyl siding,and the calibrator 50 is used to obtain the final net shape of the vinylsiding. However, it should be recognized that the vinyl siding may relaxslightly after it exits the calibrator 50 and cools down. Optionally,the vinyl siding may be passed under at least one embossing roller andat least one cooling roller and then into a water bath after exiting thecalibrator 50. The embossing roller(s) may be used to give the vinylsiding a wood-grain appearance, and the cooling roller(s) and the waterbath may be used to further cool down the vinyl siding to limit theeffect of oil canning and distortion.

In the example of FIG. 3, the calibrator 50 is comprised of a housing 52and optional inserts 54, 56, 58, 60, 62, 64. In addition, the calibratormay include at least one internal conduit to conduct at least one flowof water to help cool the calibrator 50. The flow of water may be anydesired temperature, but it is preferably between about 48 and about 52degrees Fahrenheit. The housing 52 may be comprised of any suitablematerial such as aluminum, and the inserts 54, 56, 58, 60, 62, 64 may becomprised of any suitable material such as titanium or ferro-TIC. Theinserts 54, 56, 58, 60, 62, 64 are mounted in the housing 52 and definepassageways 66, 68, 70 corresponding to the planar portions of the vinylsiding. Alternatively, the housing itself may define the passageways. Inaddition, it should be recognized that the calibrator may have only oneor any plural number of passageways as needed.

Passageway 66 has an edge 72 and edge 74. Passageway 68 has an edge 76and an edge 78, and passageway 70 has an edge 80 and an edge 82. Forease of description, the dimensions of a passageway of a calibrator ofthe present invention will be described with regard to passageway 68 ofcalibrator 50. The width of passageway 68 from edge 76 to edge 78 is atleast about 4.0 inches, more preferably at least about 5.0 inches, andstill more preferably at least about 6.0 inches. The surface variancefrom edge 76 to edge 78 is less than about 0.05 inches, more preferablyless than about 0.04 inches, and still more preferably less than about0.03125 inches. In addition, the radius curvature from edge 76 to edge78 is at least about 85 inches, more preferably at least about 117inches, and even more preferably at least about 148 inches.

EXAMPLE

A vinyl siding panel as shown in FIG. 2 was manufactured by extruding aPVC substrate composition and a PVC capstock composition. The extrusiontemperature varied between about 340 and about 360 degrees Fahrenheit.After the extruder, the vinyl was passed through a preforming guide anda first calibrator to obtain the general shape of the vinyl siding. Thevinyl was then passed through a second calibrator like the one shown inFIG. 3 at a rate of about 48 to about 50 feet per minute to obtain thefinal net shape of the vinyl siding. Each passageway of the secondcalibrator had a width of about 6.0 inches, a surface variance of about0.03125 inches, and a radius curvature of about 148.5 inches. The vinylsiding was then passed under embossing rollers to impart a wood-grainpattern. Thereafter, the vinyl siding was passed under cooling rollersand through a water bath to further cool it down. Each planar portion ofthe resulting vinyl siding had a thickness of about 0.045 inches, awidth of about 6.0 inches, a surface variance of about or less than0.03125 inches, and a radius curvature of about or more than 148.5inches. Furthermore, the height of each of the seams connecting theplanar portions was about 0.6875 inches.

The exemplary embodiments herein disclosed are not intended to beexhaustive or to unnecessarily limit the scope of the invention. Theexemplary embodiments were chosen and described in order to explain theprinciples of the present invention so that others skilled in the artmay practice the invention. Having shown and described exemplaryembodiments of the present invention, those skilled in the art willrealize that many variations and modifications may be made to affect thedescribed invention. Many of those variations and modifications willprovide the same result and fall within the spirit of the claimedinvention. It is the intention, therefore, to limit the invention onlyas indicated by the scope of the claims.

1. A vinyl siding panel unit comprising: a vinyl siding panel comprisinga first substantially planar portion extending the longitudinal lengthof the vinyl siding panel, said first substantially planar portioncomprising: a first edge and a second edge; a width of at least about4.0 inches from said first edge to said second edge; and a slightcurvature between said first edge and said second edge such that saidslight curvature has a surface variance of less than about 0.05 inchesrelative to an imaginary straight line connecting said first edge andsaid second edge; and a reinforcement panel adjacent to said firstsubstantially planar portion; wherein said surface variance isdetermined prior to said first substantially planar portion beingpositioned adjacent to said reinforcement panel; and wherein said vinylsiding panel unit simulates the appearance of straight face siding. 2.The vinyl siding panel unit of claim 1 wherein said reinforcement panelis comprised of foam.
 3. The vinyl siding panel unit of claim 1 whereinsaid first substantially planar portion has an average thickness in therange from about 0.040 inches to about 0.050 inches.
 4. The vinyl sidingpanel unit of claim 1 wherein said first substantially planar portionhas said width of at least about 6.0 inches from said first edge to saidsecond edge.
 5. The vinyl siding panel unit of claim 1 wherein saidsurface variance is less than about 0.04 inches.
 6. The vinyl sidingpanel unit of claim 1 wherein said surface variance is less than about0.03125 inches.
 7. The vinyl siding panel unit of claim 1 wherein: saidfirst substantially planar portion has said width of at least about 6.0inches from said first edge to said second edge; and said surfacevariance is less than about 0.04 inches.
 8. The vinyl siding panel unitof claim 1 further comprising a second substantially planar portionextending the longitudinal length of the vinyl siding panel, said secondsubstantially planar portion comprising: a first edge and a second edge;a width of at least about 4.0 inches from said first edge to said secondedge of said second substantially planar portion; and a slight curvaturebetween said first edge and said second edge such that said slightcurvature has a surface variance of less than about 0.05 inches relativeto an imaginary straight line connecting said first edge and said secondedge of said second substantially planar portion; wherein said secondsubstantially planar portion is connected to said first substantiallyplanar portion by a first seam to define a stepped contour; and whereinsaid reinforcement panel is adjacent to said second substantially planarportion.
 9. The vinyl siding panel unit of claim 8 wherein a height ofsaid first seam is at least about 0.5 inches.
 10. The vinyl siding panelunit of claim 8 wherein said first substantially planar portion issubstantially similar in curvature to said second substantially planarportion.
 11. The vinyl siding panel unit of claim 8 further comprising athird substantially planar portion extending the longitudinal length ofthe vinyl siding panel, said third substantially planar portioncomprising: a first edge and a second edge; a width of at least about4.0 inches from said first edge to said second edge of said thirdsubstantially planar portion; and a slight curvature between said firstedge and said second edge such that said slight curvature has a surfacevariance of less than about 0.05 inches relative to an imaginarystraight line connecting said first edge and said second edge of saidthird substantially planar portion; wherein said third substantiallyplanar portion is connected to said first substantially planar portionby a second seam to define a stepped contour; and wherein saidreinforcement panel is adjacent to said third substantially planarportion.
 12. The vinyl siding panel unit of claim 11 wherein a height ofsaid second seam is at least about 0.5 inches.
 13. The vinyl sidingpanel unit of claim 11 wherein said first substantially planar portion,said second substantially planar portion, and said third substantiallyplanar portion are substantially similar in curvature.
 14. A vinylsiding panel unit comprising: a vinyl siding panel comprising a firstsubstantially planar portion extending the longitudinal length of thevinyl siding panel, said first substantially planar portion comprising:a first edge and a second edge; a width of at least about 4.0 inchesfrom said first edge to said second edge; and a radius curvature betweensaid first edge and said second edge of at least about 85 inches; and areinforcement panel adjacent to said first substantially planar portion;wherein said radius curvature is determined prior to said firstsubstantially planar portion being positioned adjacent to saidreinforcement panel; and wherein said vinyl siding panel unit simulatesthe appearance of straight face siding.
 15. The vinyl siding panel ofclaim 14 wherein said reinforcement panel is comprised of foam.
 16. Thevinyl siding panel unit of claim 14 wherein said first substantiallyplanar portion has an average thickness in the range from about 0.040inches to about 0.050 inches.
 17. The vinyl siding panel unit of claim14 wherein said first substantially planar portion has said width of atleast about 6.0 inches from said first edge to said second edge.
 18. Thevinyl siding panel unit of claim 14 wherein said radius curvature is atleast about 117 inches.
 19. The vinyl siding panel unit of claim 14wherein said radius curvature is at least about 148 inches.
 20. Thevinyl siding panel unit of claim 14 wherein: said first substantiallyplanar portion has said width of at least about 6.0 inches from saidfirst edge to said second edge; and said radius curvature is at leastabout 117 inches.
 21. The vinyl siding panel unit of claim 14 furthercomprising a second substantially planar portion extending thelongitudinal length of the vinyl siding panel, said second substantiallyplanar portion comprising: a first edge and a second edge; a width of atleast about 4.0 inches from said first edge to said second edge of saidsecond substantially planar portion; and a radius curvature between saidfirst edge and said second edge of said second substantially planarportion of at least about 85 inches; wherein said second substantiallyplanar portion is connected to said first substantially planar portionby a first seam to define a stepped contour; and wherein saidreinforcement panel is adjacent to said second substantially planarportion.
 22. The vinyl siding panel unit of claim 21 wherein a height ofsaid first seam is at least about 0.5 inches.
 23. The vinyl siding panelunit of claim 21 wherein said first substantially planar portion andsaid second substantially planar portion are substantially similar incurvature.
 24. The vinyl siding panel unit of claim 21 furthercomprising a third substantially planar portion extending thelongitudinal length of the vinyl siding panel, said third substantiallyplanar portion comprising: a first edge and a second edge; a width of atleast about 4.0 inches from said first edge to said second edge of saidthird substantially planar portion; and a radius curvature between saidfirst edge and said second edge of said third substantially planarportion of at least about 85 inches; wherein said third substantiallyplanar portion is connected to said first substantially planar portionby a second seam to define a stepped contour; and wherein saidreinforcement panel is adjacent to said third substantially planarportion.
 25. The vinyl siding panel unit of claim 24 wherein a height ofsaid second seam is at least about 0.5 inches.
 26. The vinyl sidingpanel unit of claim 24 wherein said first substantially planar portion,said second substantially planar portion, and said third substantiallyplanar portion are substantially similar in curvature.